Project Overview
Project Type: Gas Station Power Distribution System Upgrade
Completion Date: November 2023
Location: Baghdad-Karbala Highway, Iraq
End Client: State Organization for Marketing of Oil (SOMO)
Direct Client: CPS Gas Station Operating Company
Technical Challenge & Solution
Challenge: To provide a reliable and stable power distribution system for a new, modernized CPS gas station, capable of withstanding Iraq's harsh environmental conditions (high temperatures, sand/dust, voltage fluctuations) and ensuring 24/7 uninterrupted power for fueling equipment, lighting systems, convenience stores, and security monitoring.
Solution: TSTYNICE supplied a specially engineered, high-temperature-rated 750 kVA distribution transformer designed for robust performance in demanding desert climates.
Equipment Supplied
▸ Distribution Transformer: 750 kVA, ONAN, Dyn1
▸ Voltage Ratio: 6.6 kV (±2x2.5%) / 400-231 V
▸ Impedance: 5.8% at 85°C
▸ Quantity: 1 unit
▸ Manufacturer's Reference: 7363-M, Style: A6W2HCCAN017363
▸ Mounting: Outdoor, pad-mounted
▸ Insulation & Cooling: Mineral oil, hermetically sealed / ONAN
Key Technical Features & Customizations
High-Temperature Design: Specially calibrated for a maximum ambient temperature of 50°C with a conservative winding temperature rise limited to 55°C, ensuring long-term insulation life and reliability.
Desert-Proof Construction: Enhanced anti-corrosion treatment on tank and radiators; sealed breather with silica gel; dust-proof gaskets on all openings; and sand-resistant paint finish.
Dyn1 Vector Group: Provides a neutral point on the LV side suitable for creating a stable 400/231V supply for single-phase and three-phase loads common in commercial facilities.
Optimized Impedance (5.8%): Carefully selected to balance fault current limitation for equipment protection with adequate voltage regulation under the station's load profile.
Low Loss Core: Utilized high-grade, low-loss silicon steel to minimize no-load losses, improving operational efficiency for continuous operation.
Extended Accessories: Equipped with a comprehensive protection suite including Buchholz relay, pressure relief device, dial-type temperature indicator with alarm/trip contacts, and oil level gauge.
Project Execution
Fast-Track Delivery: Completed manufacturing and testing within 10 weeks from order confirmation to meet the gas station's construction timeline.
Rigorous Pre-Dispatch Testing: Conducted full routine tests per IEC 60076, including special temperature rise test to verify performance at 50°C ambient, and impulse withstand test for grid resilience.
Logistics & Installation Support: Managed complex logistics to the jobsite; provided detailed installation drawings and manuals; offered remote guidance during installation and commissioning.
Local Compliance: Documentation and nameplate provided in both English and Arabic.
Operational Results
Reliable Power Supply: Successfully energized the entire CPS gas station complex, including high-power fuel dispensers, underground tank monitoring systems, and commercial areas.
Stable Voltage Output: Maintains voltage within ±2% under fluctuating grid conditions (common in the region), protecting sensitive electronic payment and monitoring systems.
Efficient Operation: No-load and load losses are within guaranteed limits, ensuring cost-effective operation for the client.
Robust Performance: Has operated flawlessly through the summer peak temperatures exceeding 48°C, with transformer hot-spot temperature well within safe limits.
Client Benefits
Enhanced Uptime: Reliable transformer performance is critical for 24/7 gas station operations, directly supporting business continuity and revenue.
Low Maintenance: Hermetically sealed, desert-adapted design minimizes maintenance needs in a dusty environment.
Future-Proof Capacity: 750 kVA rating provides ample headroom for future expansion, such as EV charging stations or additional retail facilities.
Safety & Protection: Integrated protective devices ensure safe operation and prevent damage to downstream assets in case of internal faults.
Total Cost of Ownership: High-efficiency design and durable construction translate to lower lifetime operating and maintenance costs.
